Boots with polymeric foam shell and exposed sock liner

Abstract

A boot comprises: a shell comprising a first foamed polymeric material; a sock liner comprising a second foamed polymeric material, the sock liner having an exposed section and an enclosed section; and an adhesive layer affixing the shell and the enclosed section of the sock liner; wherein there is an absence of intermingling of the second surface of the enclosed section of the sock liner with the inner surface of the shell. Methods of making and using the boot are also provided.

What is claimed is: 
     
       1. A boot comprising:
 a shell comprising a first foamed polymeric material comprising an ethylene vinyl acetate (EVA) polymer and a chlorinated polyurethane; and 
 a sock liner comprised of a second foamed polymeric material and comprising a liner inner surface and a second surface opposite the liner inner surface, the sock liner having an exposed section and an enclosed section, the enclosed section being enclosed by the shell; 
 wherein there is an absence of intermingling of the second surface of the enclosed section of the sock liner with an inner surface of the shell. 
 
     
     
       2. The boot of  claim 1 , wherein the shell is a unitary layer. 
     
     
       3. The boot of  claim 1  further comprising an adhesive layer affixing the inner surface of the shell and the second surface of the enclosed section of the sock liner. 
     
     
       4. The boot of  claim 1 , wherein the shell comprises a primary edge in contact with the sock liner, a front support section defined by a second edge of the shell, and a back support section defined by a third edge of the shell, wherein the primary edge extends between a front transition point with the second edge and a back transition point with the third edge such that the front transition point is at a distance from a top edge of the boot that is greater than a distance from the top edge of the boot of the back transition point. 
     
     
       5. The boot of  claim 4 , wherein the primary edge extends between the front transition point and the back transition point at an angle of greater than or equal to 30 degrees relative to the top edge of the boot. 
     
     
       6. The boot of  claim 5 , wherein the angle is greater than or equal to 45 degrees and less than or equal to 75 degrees relative to the top edge of the boot. 
     
     
       7. The boot of  claim 1 , wherein the shell further a comprises a heel counter that is continuous with a back support section. 
     
     
       8. The boot of  claim 1 , wherein the first foamed polymeric material comprises by weight the ethylene vinyl acetate (EVA) polymer in an amount in the range of from greater than to equal to 30% to less than or equal to 50%, and the chlorinated polyethylene in an amount in the range of from less than or equal to 70% to greater than or equal to 50%. 
     
     
       9. The boot of  claim 1 , wherein the second foamed polymeric material of the sock liner comprises natural rubber, polychloroprene, nitrile butadiene rubber, polyisoprene, desert guayule, or combinations thereof. 
     
     
       10. The boot of  claim 1  further comprising an outsole, the boot optionally further comprising a midsole between the outsole and the shell. 
     
     
       11. A boot comprising:
 a shell comprising a foamed polymeric material comprising an ethylene vinyl acetate (EVA) polymer and a chlorinated polyurethane; 
 a sock liner comprised of a foamed neoprene material and comprising a liner inner surface and a second surface opposite the liner inner surface, the sock liner having an exposed section and an enclosed section; and 
 an adhesive layer affixing an inner surface of the shell and the second surface of the enclosed section of the sock liner, and having a thickness spanning between the inner surface of the shell and the second surface of the enclosed section of the sock liner; 
 wherein there is an absence of intermingling of the second surface of the enclosed section of the sock liner with the inner surface of the shell. 
 
     
     
       12. The boot of  claim 11 , wherein the shell comprises a primary edge in contact with the sock liner, a front support section defined by a second edge of the shell, and a back support section defined by a third edge of the shell, wherein the primary edge extends between a front transition point with the second edge and a back transition point with the third edge such that the front transition point is at a distance from a top edge of the boot that is greater than a distance from the top edge of the boot of the back transition point. 
     
     
       13. The boot of  claim 11 , wherein the shell further comprises a heel counter that is continuous with a back support section. 
     
     
       14. The boot of  claim 11 , wherein the foamed polymeric material of the shell comprises by weight the ethylene vinyl acetate (EVA) polymer in an amount in the range of from greater than to equal to 30% to less than or equal to 50%, and the chlorinated polyethylene in an amount in the range of from less than or equal to 70% to greater than or equal to 50%. 
     
     
       15. A method of making a boot comprising:
 injecting a foamable polymeric material into a mold cavity to form a shell comprising a first foamed polymeric material comprising an ethylene vinyl acetate (EVA) polymer and a chlorinated polyurethane; 
 disposing a sock liner comprised of a second foamed polymeric material and comprising a liner inner surface and a second surface opposite the liner inner surface on a boot last; 
 supplying an adhesive to a surface of the sock liner, the shell, or both; 
 assembling the boot last on which the sock liner is disposed and the shell; 
 forming an adhesive layer between an inner surface of the shell and the second surface of an enclosed section of the sock liner, wherein there is an absence of intermingling of the second surface of the enclosed section of the sock liner with the inner surface of the shell; 
 affixing the inner surface of the shell and the second surface of the enclosed section of the sock liner to assemble an interim article; and 
 exposing the interim article to heating conditions for drying the adhesive and/or curing the adhesive to form the boot. 
 
     
     
       16. The method of  claim 15 , wherein a first adhesive-component is supplied to the second surface of the sock liner and a second adhesive-component is supplied to the inner surface of the shell such that upon contact and optionally heat, the first adhesive-component is reactive with the second adhesive-component to form the adhesive layer. 
     
     
       17. The method of  claim 15 , wherein during assembly of the boot last on which the sock liner is exposed and the shell, the shell is in an expanded state, and upon cooling and shrinkage of the shell, the adhesive layer is formed from the adhesive. 
     
     
       18. The method of  claim 15 , wherein the boot last is expandable, and wherein during assembly of the boot last on which the sock liner is exposed and the shell, the boot last is in a first deflated position, and upon supply of a pressure source to the boot last, the boot last moves from the first deflated position to a second inflated position thereby forming the adhesive layer from the adhesive.